965_0178 965 0178 Onan E125V E140V Elite Series Operator's Manual (07 1997)

User Manual: 965-0178 Onan E125V E140V Elite series Operator's manual (07-1997)

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@WQTYNM QT E%C%1%0-,\'(./

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*76:5 058659

Emissions Supplement:

900-1

021

Date:

07-2000

Insert

with-

Manual Number

&

Date:

See

Table

1

Models:

See

Table

1

965-0176

981-0153

Purpose:

This supplement for the Operator's

Manuals specified in Table

1

clarifies how com-

pliance with engine emissions regulations, includ-

ing

U.

S.

EPA Phase 2 and California Air Re-

sources Board regulations for Model Year 2000

onwards, is presented on genset and engine

nameplates (Figures

1

and 2). This sheet is to be

bound in the genset or engine manual behind the

front cover and in front of earlier Supplements, if

any.

7/97

1

BGE

/

NHE

7/97

I

KV

TABLE

1.

MANUALS AFFECTED

BY

SUPPLEMENT

Manual

No.

I

Date

1

Genset Models

965-0138

I

5/97

I

BGM

/

NHM

I

965-0175

I

7/97

1

BGD

I

NHD

I

I

981-0158

I

6/99

I

KVC

I

981-0159

I

5/00

I

KY

981-0160

I

7/99

I

MKY

I

983-0101

1

5/00

I

HGJAAIHGJABIHGJAC

1

For engines of less than 225 cc displacement,

Category C

=

125 hrs, B

=

250 hrs, A

=

500

hrs.

For engines

of

225 cc and greater displacement,

Category C

=

250 hrs, B

=

500

hrs, A

=

1000

hrs.

r

IMPORTANT ENGINE INFORMATION

CURRMlNS

POWER

GENERATlOM

1400

73rd

Avo. NE

Minneapolis,

MN

55432

Made

in

USA

Modd

No:

PH

kVA:

kW:

pf:

RPM

Ha

Bat:

wring

DiagME

InsuIatbn

-

NEMA

Qan

F

Ambiant

40°C

flhe engine family designation, engine displacement, statement

of

compliance with the applicable

EPA

and/or California emissions

regulations, including the compliance period or category; appear in

this block on the actual nameplate on the genset.]

Manual

No.

I

Date

I

Engine Models

965-0163

I

10/95

I

Miller P216

/

P218

/

P220

I

P224

FIGURE

I.

TYPICAL GENSET NAMEPLATE

965-0174

I

10/97

I

E124V Floorcare

965-0178

I

7/97

I

E125V/ E140V

I

965-0179

I

7/97

I

E125H

I

E140H

I

965-0180

I

7/97

I

P218V

I

P220V

965-0182B

1

-

I

P216

/

P218

/

P220

I

P224

I

965-0183

I

-

I

P248V Floorcare

I

Nameplate Information:

See the Operator's

Manual for the location of the actual nameplate on

the genset or engine. Figures

1

and 2 illustrate

where the information regarding compliance with

U.

S.

EPA and California Air Resources Board

regulations on the nameplate. The appropriate

figure in this supplement supercedes the nameplate

illustration in Figure 1 in the genset or engine

manual in which the supplement is bound.

Federal Emissions Compliance Period:

The

Federal Emissions Compliance Period referred

to

on the nameplate indicates the number of operating

hours for which the engine has been shown to meet

Federal emissions requirements.

f

IMPQRTAMT

ENGINE

INFORMATION

)

ONAN CORPORATION

1400

73rd

Ave.

NE

Minneapolis,

MN

55432

Made in Canada

Engine

Model:

SIN:

rhe

engine family designation, engine displace-

ment, statement of compliance with the applicable

EPA

and

/

or California emissions regulations, in-

cluding

the

compliance period

or

category; appear in

this

block on the actual nameplate on the engine.]

FIGURE

2.

TYPICAL ENGINE NAMEPLATE

Page

1

of

1

Redistribution or publication of this document, 

by any means, is strictly prohibited.

Beforeoperating the engine, read this manualand become

familiar with it and the equipment.Safe and efficient

operation canbeachieved only if the equipment is

properly operated and maintained.

The following symbols,found throughout this manual, alert you

to potentially dangerous conditions to the operator, service per-

sonnel,or the equipment.

This symbol warns of immediate hazards

which will result in severe personal injury or death.

4(/-,-+ This symbol refers toahazard or unsafe

practice whichcan result in severe personal injury or

death.

)(21,.- This symbol refers toahazard or unsafe

practice whichcan result in personal injury or product or

property damage.

Fuels,electrical equipment, batteries,exhaust gases and

moving parts present potential hazards that can result in severe

personalinjury.Take care in following these recommended

procedures.All local, stateand federalcodes should be

consulted and complied with.

4(/-,-+ This engine is not designed or intended for

usein any type of aircraft.Use of this engine in aircraft can

result in engine failureand cause severepersonal injury or

death.

GENERAL

•Provide appropriate fire extinguishers and install them in

convenient locations.Usean extinguisher rated ABC by

NFPA.

•Make sure that all fasteners on the engine are secureand

accurately torqued. Keep guards in position over fans,

driving belts,etc.

•Ifit is necessary to make adjustments while the engine is

running, useextreme caution when close to hot exhausts,

moving parts,etc.

•Used engine oils havebeen identified by some stateand

federalagencies as causing cancer or reproductive

toxicity.When checking or changing engine oil, take care

not to ingest, breathe the fumes,or contact used oil.

•Do not work on this equipment when mentally or

physically fatigued,or after consuming any alcohol or

drug that makes the operation of equipment unsafe.

BATTERIES

•Before starting work on the engine,disconnect batteries

to prevent inadvertent starting of the engine. Disconnect

negative(–) cable first.

•DO NOT SMOKE while servicing batteries.Leadacid bat-

teries give offahighly explosive hydrogen gas whichcan

beignited by flame,electricalarcing or by smoking.

•Verify battery polarity beforeconnecting battery cables.

Connect negative (–) cable last.

PROTECT AGAINST MOVING PARTS

•Donot wear looseclothing in the vicinity of moving parts,

suchas PTO shafts,flywheels, blowers, couplings,fans,

belts,etc.

•Keep your hands away from moving parts.

FUEL SYSTEM

•DO NOT fill fuel tanks while engine is running.

•DO NOT smoke or usean open flame in the vicinity of the

engine or fuel tank. Internalcombustion engine fuels are

highly flammable.

•Fuel line must be of steel piping,adequately secured, and

free from leaks.Piping at the engine should beapproved

flexible line. Do not usecopper piping for flexible lines as

copper will work harden and become brittle enough to

break.

•Be sureall fuel supplies haveapositive shutoff valve.

•Benzene and lead,found in some gasoline,havebeen

identified by some stateand federalagencies as causing

cancer or reproductive toxicity.When checking,draining

or adding gasoline, take care not to ingest, breathe the

fumes,or contact gasoline.

EXHAUST SYSTEM

•Exhaust products of any internalcombustion engine are

toxicand cancause injury,or death if inhaled. When

operating the engine in a confined area, make sure the

ventilation system is operating properly.

•DO NOT use exhaust gases to heat a compartment.

•Make sure that your exhaust system is free of leaks.Make

sure that exhaust manifolds are secureand are not

warped by bolts unevenly torqued.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, a poisonous gas that

cancause unconsciousness and death. It is an odorless and

colorless gas formed during combustion of hydrocarbon fuels.

Symptoms of carbon monoxide poisoning are:

•Dizziness •Vomiting

•Headache •Muscular Twitching

•Weakness and Sleepiness •Throbbing in Temples

If you experienceany of these symptoms,get out into freshair

immediately, shut down the unit and do not use it until it has

been inspected.

The best protection against carbon monoxide inhalation is

proper installation and regular,frequent inspections of the

completeexhaust system. If you noticea change in the sound

or appearanceof exhaust system, shut the unit down immedi-

ately and have it inspected and repaired at onceby a competent

mechanic.

KEEP THE UNIT AND SURROUNDING AREA CLEAN

•Make sure that oily rags are not left on or near the engine.

•Removeall unnecessary greaseand oil from the unit.

Accumulated greaseand oil cancause overheating and

subsequent engine damage and present apotential fire

hazard.

Safety Precautions

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by any means, is strictly prohibited.

1

Title Page

Safety PrecautionsInside Front Cover........................................................

Introduction 2...............................................................................

Operation 5................................................................................

Periodic Maintenance8......................................................................

Adjustments 13............................................................................

Troubleshooting 17.........................................................................

Specifications18...........................................................................

Important Information for California Engine Users 19. ..........................................

WARNING Improper service or replacement of parts

can result in severe personal injury and equipment

damage. service personnel must be qualified to perform

electricaland/or mechanical service.

CALIFORNIA PROPOSITION 65WARNING

Engine exhaust from this product contains chemicals

known to the State of California tocausecancer, birth

defects,and other reproductive harm .

Table of Contents

Redistribution or publication of this document, 

by any means, is strictly prohibited.

2

ABOUT THIS MANUAL

This manualcovers the operation and maintenance

of the vertical-shaft EliteSeries of engines.Each

operator of the power equipment should study this

engine manualcarefully and observeall of its

instructions and precautions.Proper useand peri-

odicmaintenanceare responsibilities of the opera-

tor(s)and are essential for top performance.

MODEL IDENTIFICATION

Whenever contacting anOnan dealer or distributor

for information,parts or service, always provide the

model number and the serial number marked on the

nameplateof the engine. Figure 1 illustrates a typi-

cal engine nameplateand Figure 2 the location of

the nameplate on the engine.

Genuine Onan replacement parts obtained from an

Onandealer or distributor are recommended.

E140V–N/11264D

L951234567

390SN5390U1G2RA

THIS ENGINE MEETS U.S.EPAPH1AND 1995–1998

CALIFORNIA EMISSIONS REGULATIONS FOR ULGE ENGINES

FIGURE 1. TYPICAL ENGINE NAMEPLATE

Introduction

Redistribution or publication of this document, 

by any means, is strictly prohibited.

3

AIR CLEANER

OIL FILTER

BATTERY CHARGING

VOLTAGE REGULATOR

(On engines equipped

with electric starter)

RECOIL STARTER

(If so equipped)

ENGINE

NAMEPLATE

ELECTRIC STARTER

(If so equipped)

OIL DRAIN

FUEL FILTER

OIL FILL CAP

AND DIPSTICK

=\)''.

=\)''-

SPARK PLUG

GOVERNOR ARM

(see Adjustments)

GOVERNOR SHAFT

(see Adjustments)

ENGINE

CONTROL PLATE

(see Adjustments)

CRANKSHAFT

FLYWHEEL AIR

INLET SCREEN

FIGURE 2.TYPICAL ENGINE CONFIGURATION

Redistribution or publication of this document, 

by any means, is strictly prohibited.

4

FUEL RECOMMENDATIONS

Useclean,fresh unleaded gasoline having amini-

mum octane rating (Anti-KnockIndex) of 87.

During some times of the year only mandated “oxy-

genated” gasolines may beavailable. Theseare

acceptable for use, but not preferable. Leaded gas-

oline may be used but will result in the extramainte-

nance required for removing combustion chamber

and spark plug deposits.Do not use gasoline or

gasoline additives (de-icers)containing methanol

becausemethanol canbecorrosive to fuel system

components.

)(21,.- Do not use gasoline or gasoline ad-

ditives containing methanol because methanol

canbecorrosive to fuel system components.

Avoid using highly leaded gasolines and lead

additives because of the extraengine mainte-

nance that will be required.

4(/-,-+ Gasoline is highly flammable and

cancause severe personal injury or death. Do

not smoke if you smell gasoline or are near fuel

tanks or gasoline-burning equipment or are in

anarea sharing ventilation with such equip-

ment.Keep flames, sparks,pilot lights,electri-

calarcs and arc-producing equipment and all

other sources of ignition well away.

ENGINE OIL RECOMMENDATIONS

Use premium quality motor oil. Look for the API

(AmericanPetroleumInstitute) classification and

useClass SG or SH oil (alsoSG/CD, SG/CE, SH/

CD or SH/CE). Also look for the SAE (Society of Au-

tomotiveEngineers) viscosity grade. Referring to

Table 1, choose the viscosity grade appropriate for

the ambient temperatures expected during the peri-

od of time until the next scheduled oil change.

Single-grade SAE 30 oil is preferable when temper-

atures areconsistently above freezing. Multigrade

oils arebetter when wide temperature variations

areexpected.

TABLE 1. OIL VISCOSITY VS.TEMPERATURE

EXPECTED AMBIENT

TEMPERATURES

SAE

VISCOSITY

GRADE

32°F(0°C)and higher30

10 °F to 100°F(–12°C to 38 °C)15W-40

(OnaMax)

0 °F to 80 °F(–18°C to 27°C)10W-30

10W-40

–20°F to 50 °F(–28°C to 10 °C)5W-30

STARTING BATTERIES

Anengine equipped withan electric starter requires

a12 volt starting battery.Prompt starting requires

sufficient battery capacity and battery cable size.

Neither cranking performance nor starter service

life will be satisfactory withan undersized battery.

Regular,monthly maintenance of batteries may be

required. See Periodic Maintenanceand any

instructions available from the equipment or battery

manufacturer.It should be noted that as long as the

equipment is operated regularly, the automatic bat-

tery recharging system on the engine should be

able to maintain battery charge. See OUT-OF-

SERVICE PROTECTION under Operation regard-

ing battery care during storage for prolonged peri-

ods.

EXHAUST SYSTEM

EXHAUST GAS IS DEADLY!Mobile engine-pow-

ered equipment must never be operated inside

buildings or other enclosed spaces without ample

freshair ventilation.

Stationary engine-powered equipment installed in-

side buildings or other enclosed spaces must be

equipped withaleak-free exhaust system that car-

ries all exhaust gases to the outside, well away from

all windows,doors, vents and other openings into

the building or enclosure.

It is the responsibility of the equipment operator(s)

tocheck for exhaust leaks on adaily basis and to

haveall leaks repaired beforecontinuing to operate

the equipment.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

5

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas.Carbon monoxide is poi-

sonous and cancause unconsciousness and death. Symptoms of carbon monoxide poisoning in-

clude:

•Dizziness •Throbbing in Temples

•Nausea•Muscular Twitching

•Headache •Vomiting

•Weakness and Sleepiness •Inability toThink Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH

AIR IMMEDIATELY.If symptoms persist, seek medicalattention. Shut down the engine and do not

operateit until it has been inspected and repaired.

Make certain the exhaust system is properly installed. Inspect it every time the engine is started

and after every eight hours of continuous operation.

PRE-START CHECKS

Before the first start of the day and after every eight

hours of operation perform the maintenance

instructed in DAILY(8 HOUR)MAINTENANCE un-

derPeriodic Maintenance .Keep alog of mainte-

nanceand the hours runand performany mainte-

nance that may be due. Also,if the equipment has

been in storage, return the engine to serviceas

instructed under RETURNING THE ENGINE TO

SERVICE in this section.

Always follow the equipment manufacturer’s oper-

ating instructions and observeall precautions when

operating power equipment.

4(/-,-+ Moving parts cancause severe

personalinjury or death. Hot exhaust parts can

cause severeburns.Stay clear of hot or moving

parts.Make sureall protective shields and

guards are secure in placebefore starting up

the equipment.

STARTING

1. Check the oil level if this is the first start of the

day and add oil as necessary.

)(21,.- Starting the engine without oil

will cause severe engine damage. Always

keep the engine oil level between the Full

and Add marks on the dipstick.

2.Fill the fuel tank,if necessary, and open any fuel

line shutoff valve.

3.Release the clutch if the engine is so equipped.

4. Onequipment witha single throttle/choke con-

trol,push the knobor lever to its “start” or

“choke” position. On equipment with separate

controls,pull the choke knobout to its full-choke

position.

Note:Try starting without the choke in warm

weather or when the engine is warm.

5. Push the throttle knobor lever to the middle of

its speed range.

6.If so equipped, turn the ignition key switch to its

runposition.

7.Pull the recoil starter handle tocrank the en-

gine. If the engine is equipped withan electric

starter, turn the key switch to its start position

and hold it there until the engine starts.Do not

crank for more than 30 seconds at a time and

wait at least one minutebetween tries when

cranking withan electric starter.See Trouble-

shooting if the engine does not start after sever-

al tries.

8. After the engine starts,keep your hand on the

choke knob and slowly push it in to the full-open

choke position,pulling back if necessary to

keep the engine running smoothly. (On single-

control systems,move the knobor lever away

from the “start” or “choke” position to the “fast”

or “high” speed position.) The colder the weath-

er the longer it will take the engine to start run-

ning smoothly with the choke fully open. Do not

operate the equipment until the engine has

warmed up sufficiently to run smoothly with the

choke fully open.

Operation

Redistribution or publication of this document, 

by any means, is strictly prohibited.

6

ENGINE BREAK-IN

Engine break-in as a result of proper care during the

first hours of operation of anew or rebuilt engine re-

sults in the ideal fitting of all internal moving metal

parts, which is essential for top engine perfor-

mance. For controlled engine break-in:

1. Operate the equipment as it is intended tobe

operated. However,for the first 1-1/2 hours,if

possible,operate the equipment at about half

the available engine power,occasionally oper-

ating at full engine power for brief periods.

Also,if possible, avoid prolonged low-speed,

low-power operation during engine break-in.

2.Proper engine oil is especially critical during

break-in because of the higher engine temper-

atures that canbe expected. See REC-

OMMENDED ENGINE OIL in Introduction.

Change the oil if it is not appropriate for the am-

bient temperatures during the break-in period.

See Table 1.

3.Check the oil level twiceaday or after every 4

hours of operation during the first 24 hours of

operation.

4. Change the oil and oil filter after the first 24

hours of operation and have the valves read-

justed by aqualified mechanic.

OPERATION IN DUSTY CONDITIONS

1. Keep the engine cooling fins and flywheel air

inlet screen clean.

2.Performair cleaner maintenance more often

thannormal—as required. See Table 2.

3.Change the engine oil and oil filter more often

than normal. See Table 2.

OPERATION IN HOT WEATHER

Pay particular attention to the following items when

operating the engine in temperatures above 100°F

(38°C):

1. Keep the flywheel air inlet screen and cylinder

cooling fins clean. See to it that nothing ob-

structs air flow toand from the engine.

2.Check the oil level more frequently.

3.Change the oil and oil filter moreoften than nor-

mal. See Table 2.

4. Make sure the engine oil viscosity is appropri-

atefor the ambient temperatures and change

the oil if necessary.See Table 1.

OPERATION IN COLD WEATHER

Pay particular attention to the following items when

operating the engine in temperatures below freez-

ing:

1. Make sure the engine oil viscosity is appropri-

atefor the ambient temperatures and change

the oil if necessary.See Table 1. If the tempera-

turedrops before you have the chance to

change the oil, warm up the engine by moving

the equipment intoaheated spacebeforeat-

tempting to start the engine or change oil.

4(/-,-+ EXHAUST GAS IS DEADLY!

Never operate mobile engine-powered

equipment indoors without ample freshair

ventilation.

2.Use fresh fuel and fill the fuel tank after each

day’s use to reduce problems with moisture

condensation.

3.Keep the battery in a well-charged condition.

4. After each use push the equipment throttle

knobor lever to the middle of its speed range so

that if ice forms on the linkage during storage it

will be easier to start the engine.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

7

OUT-OF-SERVICE PROTECTION

Protect anengine that will be out of service for more

than 30 days as follows:

1. Run the engine until it reaches normal operat-

ing temperature, shut off the fuel supply and let

the engine run until it stops.Also,if the equip-

ment will not be operated for more than 120

days,add afuel preservative (OnaFresh TM) to

the equipment fuel tank. Follow the instructions

on the container label. Unless apreservative

(stabilizer)is added, the gasoline will deterio-

ratecausing fuel system corrosion,gum forma-

tion and varnish-like deposits whichcan lead to

hard starting and rough operation.

4(/-,-+ Gasoline preservatives (stabi-

lizers)are toxic.Follow the instructions on

the container label. Avoid skin contact.

Wash your hands with soapand water after

dispensing the fluid.

2.Drain the oil from the engine while it is still

warm. Refill withfresh oil and attacha tag stat-

ing the viscosity of the oil used.

3.Remove the spark plugand squirt 1 ounce

(2 tablespoons or 28 grams) of rust inhibitor or

SAE 30 oil into the cylinder.Crank the engine

over afew times and reinstall the spark plug.

4. Performair cleaner maintenanceas instructed

in Periodic Maintenance .

5. Clean the governor linkage and wrap it witha

cleancloth for protection.

6.Plug the exhaust outlet to prevent moisture,

dirt,bugs,etc. from entering.

7.Provide a suitable cover for the entire unit.

8. If so equipped,disconnect the battery (nega-

tive[–] cable first)and follow the battery or

equipment manufacturer’s storage instruc-

tions.

RETURNING THE ENGINE TO SERVICE

1. Remove the cover and all protective wrapping

and the plug from the exhaust outlet.

2.Check the tag on the oil base. Change the oil if

the viscosity is not appropriate for the expected

ambient temperatures.See Table 1.

3.Check the fuel filter and fuel lines to make sure

they are secureand havenocracks or leaks.

4. Check to see that the choke, throttle and gover-

nor linkages move freely.

5. If so equipped, cleanand check the battery ac-

cording to the battery or equipment manufac-

turer’s instructions and connect the battery

cables (positive[+ ] cable first).

6.Start the engine. The initial startup may be slow

and there may be smoke and rough operation

for afew minutes until the oil in the cylinder

burns off. If the engine does not start, cleanor

replace the spark plugas it may havebeen

fouled by the oil added to the cylinder when the

equipment was stored.

OnaFreshis a trademark of the OnanCorporation.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

8

Periodicmaintenance is essential for top engine

performance. UseTable 2 as aguide for normal pe-

riodicmaintenance. Under hot or dusty operating

conditions some maintenance operations should

beperformed more frequently, as indicated by the

footnotes in the table. Keep alog of maintenance

performed and the hours run. Recording mainte-

nance will help you keep it regular and provide a ba-

sis for supporting warranty claims.

Maintenance, replacement or repair of emission

control devices and systems may be performed by

any engine repair establishment or individual. How-

ever, warranty work must becompleted by an

authorized Onan dealer or distributor.

TABLE 2.PERIODIC ENGINE MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

MAINTENANCE OPERATION Every Day

or Every 8

Hours

Every 50

Hours Every

MonthEvery 100

HoursEvery

200 Hours Every 400

Hours

Inspect Engine • 1

CheckOil Level •

CleanAir Cleaner FoamWrapper• 3

CleanCylinder Cooling Fins• 3

CheckStarting Battery (if so equipped) • 5

Change Engine Oil and Oil Filter• 2,3,4

ReplaceFuel Filter (if so equipped) •

ReplaceAir Cleaner Element• 3

Adjust Engine ValveClearance• 2,6

Inspect,Cleanand Re-gapSparkPlug•

ReplaceSparkPlug•

1Checkfor oil,fuel and exhaust leaks,loose parts and unusual noises and vibrations.

2Performafter the first 24 hours of operation as apart of engine break-in.

3Perform more often when operating in dusty conditions.

4Perform more often when operating in hot conditions.

5See instructions for battery care provided by the equipment or battery manufacturer.

6Must be performed by aqualified mechanic(equipment or Onan dealer).

Periodic Maintenance

Redistribution or publication of this document, 

by any means, is strictly prohibited.

9

DAILY(8 HOUR)MAINTENANCE

The operator should check the following before the

first start of the day and after every eight hours of

operation:

1. Inspect fuel lines and fittings for leaks.Repair

leaks immediately.

2.Look and listen for exhaust system leaks while

the engine is running. Look for cracks and se-

vere rusting in the muffler and tailpipe. Haveall

leaks repaired beforecontinuing to operate the

equipment.

4(/-,-+ Hot exhaust parts cancause

severeburns.Allow the engine time tocool

before servicing the exhaust system.

3.Check the engine for dirt and debris and clean

the flywheel air inlet screen and cylinder cool-

ing fins as necessary.

)(21,.- A clogged flywheel air inlet

screen or dirty cooling fins cancause over-

heating and engine damage. Keep the cool-

ing fins and air inlet screen clean.

4. Check the engine oil level. The equipment

must be parked on alevel surfaceand the en-

gine stopped. Toget anaccurate reading, wait

aminute or so toallow the oil to settle in the

crankcaseif the engine has been running.

4(/-,-+ Crankcase pressurecanblow

hot engine oil out the fill tubecausing se-

vereburns.Always stop the engine before

removing the oil fill cap.

Turn the oil fill cap (Figure 3)counterclockwise

and then lift it from the fill tube. Wipe the dip

stickcleanand push it back into the oil fill tube

until the cap seats and then withdraw it tocheck

the oil level.

If the oil level is low, add API Class SG or SH oil

(alsoSG/CD, SG/CE, SH/CD or SH/CE) hav-

ing anSAE viscosity grade appropriate for the

expected temperatures, as indicated by

Table 1.

DO NOT FILL TO A LEVEL ABOVE THE FULL

MARK ON THE DIPSTICK.Drain the excess

oil if too much has been added.

)(21,.- Too much oil cancause high oil

consumption,high operating temperatures

and oil foaming. Too little oil cancause se-

vere engine damage. Keep the oil level be-

tween the Full and Add marks on the dip-

stick.

Reinstall the dipstickand capafter checking or

adding oil, turning it clockwise until it is secure.

<C\((0)

FIGURE 3.OIL FILL CAP AND DIPSTICK

Redistribution or publication of this document, 

by any means, is strictly prohibited.

10

ENGINE OIL AND FILTER CHANGE

4(/-,-+ Stateand federalagencies have de-

termined that contact with used engine oil can

causecancer or reproductive toxicity.Take

care to limit skin contact and breathing of va-

pors as muchas possible. Use rubber gloves

and wash exposed skin.

Refer toTable 2 for scheduled oil change and filter

replacement.See Figure 2 on page 3 for oil filter

and oil drain locations.

1. Run the engine until it is warm. Stop the engine

and disconnect the spark plugand,if so

equipped, the battery (negative[–] cable).

4(/-,-+ Accidental starting of the en-

gine can result in severe personal injury or

death. Always disconnect the spark plug

and the battery (negative[–] cable) before

changing oil.

2.Remove the oil fill cap.

4(/-,-+ Crankcase pressurecanblow

hot engine oil out the fill opening causing

severeburns.Always stop the genset be-

fore removing the oil fill cap.

3.Placeapan under the oil drain opening and re-

move the oil drain plug. Reinstall the plug se-

curely after the oil has drained completely.

4. Spin off the oil filter canister,drain the oil and

discard the filter according to local regulations.

5. Thoroughly wipe off the filter mounting surface.

6.Make sure the gasket is in place on the filter

canister and apply a thin film of oil to the gasket.

7.Spin on the new filter canister by hand until the

gasket just touches the mounting padand then

turn it anadditional 1/2 to 3/4 turn. Do not over-

tighten.

8. Refill withAPI Class SG or SH oil (alsoSG/CD,

SG/CE, SH/CD or SH/CE) having anSAE vis-

cosity grade appropriate for the expected tem-

peratures,as indicated by Table 1. See Speci-

ficationsfor the oil capacity.

DO NOT FILL TO A LEVEL ABOVE THE FULL

MARK ON THE DIPSTICK.Drain the excess

oil if too much has been added.

)(21,.- Too much oil cancause high oil

consumption,high operating temperatures

and oil foaming. Too little oil cancause se-

vere engine damage. Keep the oil level be-

tween the Full and Add marks on the dip-

stick.

9. Reconnect the spark plugand battery.

10.Start the engine and run it for a short time while

checking for oil leaks around the drain plugand

oil filter.Do not overtighten: tighten only as nec-

essary to eliminate leaks.

11.Used oil is harmful to the environment.Pour

the used oil intoa sealed container and deliver

it to the nearest recycling center.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

11

AIR CLEANER MAINTENANCE

Refer toTable 2 for scheduled foam wrapper main-

tenanceand air cleaner element replacement.See

Figure4.

FoamWrapper Maintenance

When performing maintenance on the foam wrap-

per only,do not remove the inner air cleaner cover.

Removeand wash the foam wrapper in water and

detergent.Squeeze the foam wrapper dry like a

sponge. Rinse withclean water and allow it to dry.

Coat the wrapper evenly with one tablespoon

(14 grams)of SAE 30 engine oil. Knead the oil into

the wrapper and wring out the excess oil.

Failure toadequately wring out excess oil from the

wrapper may causeadrop in engine power due toa

restriction of inlet air.

Install the foam wrapper over the paper air cleaner

element by stretching it over the inner cover.Com-

pletely cover all exposed paper pleats on the air

cleaner paper element.Replace the foam wrapper

when it becomes torn or stretched.

Air Cleaner Element Replacement

Tokeep anything from entering the carburetor and

engine while the air cleaner element is off,pull the

chokeknob to the full-choke position toclose the

choke plate in the carburetor.Remove the outer

cover and wipe away loose dust and debris from the

air cleaner assembly.Remove the inner air cleaner

mounting nut and cover.Remove the air filter paper

element and foam wrapper from the engine. Wipe

off dust and debris from the air cleaner base.

Install the new paper element and secure it with the

inner cover and mounting nut.Tighten the nut 1-1/2

turns after seating it on the cover.Reinstall the foam

wrapper and outer cover.

MOUNTING NUTFOAM WRAPPER

AIR CLEANER

ASSEMBLY BASE AIR CLEANER ELEMENT

SEAL

OUTER COVERINNER COVER

MOUNTING NUT

FIGURE 4. AIR CLEANER ASSEMBLY

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by any means, is strictly prohibited.

12

COOLING SYSTEM MAINTENANCE

Refer toTable 2 for scheduled cleaning of the cylin-

der cooling fins.

Usecompressed air or apressure washer toclean

the cylinder cooling fins.Take the following precau-

tions.

1. Wear safety glasses.

4(/-,-+ Always wear safety glasses

when using compressed air or apressure

washer toavoid severe eye damage.

2.Let the engine cool,especially when using a

pressure washer.The temperature stresses

caused by cleaning ahot engine cancrack the

cylinder.

3.Observeall of the manufacturer’s instructions

and precautions when using apressure

washer.

FUEL FILTER REPLACEMENT

Refer toTable 2 for scheduled fuel filter replace-

ment and Figure 2 for the location of the fuel filter (if

so equipped). Also refer to the equipment Opera-

tor’s Manual regarding any supplemental fuel filters

that may havebeen provided and the recom-

mended frequency for their replacement.

Take care not to spill fuel when disconnecting the

fuel line from the filter.Allow the engine tocool be-

foredisconnecting the fuel line so that it cannot ig-

niteany fuel that may be spilled. Closeany shutoff

valve that may be provided in the fuel line. If the filter

is of the in-line type,it is usually removable by loos-

ening the inlet and outlet hoseclamps.

4(/-,-+ Gasoline is highly flammable and

cancause severe personal injury or death.

Let the engine cool and closeany fuel line shut-

off valvebefore disconnecting the fuel line from

the filter.

Donot smoke if you smell gasoline or are near

fuel tanks or gasoline-burning equipment or are

in anarea sharing ventilation with such equip-

ment.Keep flames, sparks,pilot lights,electri-

calarcs and arc-producing equipment and all

other sources of ignition well away.

SPARK PLUG MAINTENANCE AND

REPLACEMENT

Refer toTable 2 for scheduled spark plug inspection

and replacement and toSpecificationsfor gap

specifications.

To prevent crossthreading the spark plugalways

threadit in by hand until it seats.If the spark plug is

being reused, turn it witha wrenchanadditional 1/4

turn. If the spark plug is new, turn it anadditional 3/8

to1/2 turn. If you havea torque wrench, tighten the

sparkplug to 20 lbs-ft (26 N-m).

Redistribution or publication of this document, 

by any means, is strictly prohibited.

13

CARBURETOR ADJUSTMENTS

Theseengines have precision-manufactured car-

buretors whichare not adjustable.

ENGINE SPEED AND CHOKE

ADJUSTMENTS

Normally there is no need toadjust engine speed.

Theseinstructions are for the equipment manufac-

turer in setting upand adjusting the equipment.

When setting up the equipment, Engine Speed Ad-

justments,Choke Adjustment and Control Cable

Adjustments must be performed in the order they

appear in this section.

Service personnel should note that following reas-

sembly of either the carburetor or intake manifold to

the engine,it is necessary to reposition the gover-

nor arm (Figure 2) on the governor shaft BEFORE

making speed adjustments soas tocompensate for

the slightly different alignment of parts.See the en-

gine ServiceManual.

Engine speed adjustment must beattempted only

by aqualified mechanic and the adjustments must

bemade using anaccurate tachometer.Set the

low-idle and high-idle speeds to the values speci-

fied in the equipment Operator’s Manual. In the ab-

senceof such specifications it is recommended that

low-idle speed beadjusted to 1400 RPM and high-

idle speed to 3400 RPM.

4(/-,-+ Adjusting the engine speed toa val-

ueabove that specified by the equipment

manufacturecould cause the equipment to op-

erateat speeds in violation of Federaland State

Standards for Safety for the equipment.

4(/-,-+ Moving parts cancause severe per-

sonalinjury or death. Take care when measur-

ing engine speed witha tachometer and follow

the meter instructions.You must beaqualified

mechanic.

Adjustments

Redistribution or publication of this document, 

by any means, is strictly prohibited.

14

Engine Speed Adjustments

Referring toFigures 5and 6, adjust high-idle and

low-idle as follows:

1. Remove the outer cover of the air cleaner (Fig-

ure 4) for easier access toadjustments and set

up the tachometer according to the instructions

with the tachometer.

2.Start the engine,observing all of the equipment

manufacturer’s instructions and precautions.

3.While the engine is running,move the throttle

control lever on the engine control plate toalign

its lock pin hole with the corresponding hole in

the control plateand insert apin (1/8 inch drill

bit) to lock the lever in place. Loosen the throttle

cable clamp if necessary.

4. Loosen the choke rod swivel clamp screw and

push the choke rod towards the carburetor so

that the choke will be fully open.

5. Adjust high-idle speed to specifications by

rotating the engine control platearound its piv-

ot bolt—away from the carburetor to increase

speed and toward the carburetor to decrease

speed. To do this,loosen the control plate pivot

bolt 1/8 turnand the the control plate set bolt

1/4 turn. Retighten both of the control plate

bolts upon obtaining the specified speed. Re-

checkand readjust the high-idle speed if nec-

essary.

6.Adjust low-idle speed to specifications by

turning the idle speed screw on the carburetor.

First release the throttle control lever by remov-

ing the lock pin inserted in Step 3 and then

moveit down to its lowest position.

7.Shut off the engine and readjust the choke. See

Choke Adjustment in this section.

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Do not loosen the CONTROL PLATE PIVOT AND

SET BOLTS unless you areaqualified mechanic

and haveanaccurate tachometer to set the

high-idle speed in accordance with the equipment

manufacturer’s specifications

FIGURE 5. ENGINE SPEED ADJUSTMENTS

94<5 C@554 14:ECD9>7

C3B5G ?> 31B2EB5D?B

FIGURE 6.IDLE SPEED SCREW

Redistribution or publication of this document, 

by any means, is strictly prohibited.

15

Choke Adjustment

Theseinstructions presume that engine speed ad-

justments havealready been made or that readjust-

ments areconsidered unnecessary.Referring to

Figure 7, readjust the choke as follows:

1. Shut off the engine and remove the outer cover

of the air cleaner for easier access toadjust-

ments and the filter element tobeable to view

the position of the choke plate. See Figure 4.

2.Loosen the choke rod swivel clamp screw so

that the rod is free to move in the choke swivel

clamp.

2.Move the throttle control lever on the engine

control plate toalign its lock pin hole with the

corresponding hole in the control plateand in-

sert apin (1/8 inch drill bit) to lock the lever in

place. Make sure the pin extends aboveand

past the choke lever, as shown, to function as a

stop for the choke lever.Loosen the throttle

and choke cable clamp(s) if necessary.

3.Push the choke rod towards the carburetor,

making sure the choke is fully open.

4. Rotate the choke lever towards the carburetor

until the lever bears against the pin stop and

tighten the choke rod swivel clamp screw.

5. Remove the lock pin in the control plateand

checkoperation of the choke linkage. If the

linkage binds, replace the components that are

damaged.

6.Reassemble the air cleaner.

7.Adjust the throttle and choke control cables.

See Control Cable Adjustments in this section.

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6?B D85 <5F5B

<?3; @9>

8?<5

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#KNPQTM LUTYWUR VRJYN$

D8B?DD<5

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<5F5B

5>79>5

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38?;5 B?4

31B2EB5D?B 38?;5 @<1D5

#ZQXQKRN [PNT YPN JQW OQRYNW NRNSNTY QX WNSUZNM$

FIGURE 7.CHOKE ADJUSTMENT

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by any means, is strictly prohibited.

16

Control Cable Adjustments

Theseinstructions presume that engine speed and

choke adjustments havealready been made or that

readjustments areconsidered unnecessary.

The equipment may have either a single-cable or a

two-cable system for throttle and choke control.

Single-Cable Control Systems:Referring toFig-

ure 8, adjust the throttle/choke cable as follows:

1. Shut off the engine and loosen the throttle

cable clamp.

2.Move the throttle control lever on the engine

control plate toalign its lock pin hole with the

corresponding hole in the control plateand in-

sert apin (1/8 inch drill bit) to lock the lever in

place. Push the speed control lever on the

equipment to the high speed position (not to

the “start”or “choke” position—see the illustra-

tion).

3.Hook the cable wire into the throttle control le-

ver,if necessary,pull out the cable slackand

tighten the cable clamp. Remove the lock pin in

the control plate.

Two-Cable Control Systems:Referring toFig-

ure 8, adjust the throttle and choke cables as fol-

lows:

1. Shut off the engine and loosen the throttle

cable clamp.

2.Move the throttle control lever on the engine

control plate toalign its lock pin hole with the

corresponding hole in the control plateand in-

sert apin (1/8 inch drill bit) to lock the lever in

place. Push the speed control lever on the

equipment to its highest speed position.

3.Hook the cable wire into the throttle control le-

ver,if necessary,pull out the cable slackand

tighten the cable clamp. Remove the lock pin in

the control plate.

4. Pushin the equipment choke knob to its full-

open position.

5. Hook the cable wire into the choke control le-

ver,if necessary,push the choke rod towards

the carburetor,pull out the cable slackand

tighten the cable clamp.

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D? B5=?F5 312<5 C<13;

38?;5 312<5 3<1=@ ?>

DG?\312<5 CICD5=C

#UT UYPNW XQMN UO VRJYN$

D8B?DD<5

3?>DB?<

<5F5B

@E<< 312<5

C851D8

D89C G1I

D? B5=?F5

312<5

C<13;

DI@931< C9>7<5\312<5

5AE9@=5>D D8B?DD<5&38?;5

3?>DB?<

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FIGURE 8. CONTROL CABLE ADJUSTMENTS

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by any means, is strictly prohibited.

17

Table 3 provides basic troubleshooting guidance. If

you fail to resolve the problem after taking the cor-

rectiveactions suggested, contact the equipment

or Onan dealer.

4(/-,-+ Many troubleshooting procedures

present hazards that can result in severe per-

sonalinjury or death. Only qualified serviceper-

sonnel with knowledge of fuels,electricity, and

machinery hazards should perform service pro-

cedures.Review the safety precautions on the

inside cover page.

4(/-,-+ Hot engine parts cancause severe

burns.Always allow the engine time tocool

beforeperforming any maintenance or service.

TABLE 3.TROUBLESHOOTING

Problem CorrectiveAction

1. The engine fails tocrank (elec-

tric start engines). a.Release the clutch (if so equipped).

b.Cleanand tighten the positive( + )and negative( –)battery

cable connections at the battery and the engine.

c.Recharge the battery.Refer to the equipment or battery

manufacturer’s recommendations.

2.The engine cranks slowly (elec-

tric start),or the recoil starter is

hard to pull.

a.Release the clutch (if so equipped).

b.Ifelectric start, cleanand tighten the positive( + )and nega-

tive( –)battery cable connections at the battery and the en-

gine.

c.If electric start, recharge the battery.Refer to the equip-

ment or battery manufacturer’s recommendations.

d. Change engine oil tooil having the proper viscosity for the

ambient temperature. See Table 1.

3.The engine cranks but fails to

start.a.Check the fuel tank and fill if necessary.

b.Open any closed fuel shut off valve.

c.Check engine oil level and add oil as necessary.

d. Reconnect and reclamp the choke and throttle cables,if

necessary.See Adjustments.

e. Service the air cleaner.

f. Replace the fuel filter(if provided).

g. Inspect and clean or replace the spark plugand re-gap it.

4. The engine runs and then stops.a.Check the fuel tank and fill if necessary.

b.Check the engine oil level and add oil as necessary.Drain

excess oil if the level is above the dipstickFull mark.

c.Reconnect and reclamp the choke and throttle cables,if

necessary.See Adjustments.

5. The engine exhausts black

smoke. a.Service the air cleaner.

b.Reconnect and reclamp the choke and throttle cables,if

necessary.See Adjustments.

Troubleshooting

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18

MODEL E125VMODEL E140V

Engine Type 1-Cylinder,4-Stroke Cycle, Spark-Ignited, OHV, Air-Cooled.

Vertical-Shaft

Bore3.31 inches (84.2 mm) 3.31 inches (84.2 mm)

Stroke 2.76 inches (70.0 mm) 2.76 inches (70.0 mm)

Displacement23.7 inches 3(390 cc)23.7 inches 3(390 cc)

Compression Ratio 8.5 :18.5 :1

Power at Rated Speed (3600 RPM)12.5 HP (9.3 kW)14.0 HP (10.4 kW)

Oil Capacity (withFilter)*1.7 quart (1.6 l) 1.7 quart (1.6 l)

Intake ValveClearance (Cold) 0.006 inches (0.15 mm) 0.006 inches (0.15 mm)

Exhaust ValveClearance (Cold) 0.006 inches (0.15 mm) 0.006 inches (0.15 mm)

SparkPlugGap0.035 inches (0.89 mm) 0.035 inches (0.89 mm)

SparkPlugTightening Torque20 lbs-ft (26 N-m) 20 lbs-ft (26 N-m)

Ignition Timing (Non-adjustable,elec-

tronic, magneto ignition) 23°BTDC 23°BTDC

*–See Periodic Maintenancefor oil filling instructions.

Specifications

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19

Theseengines meet the requirements of Califor-

nia’s Exhaust Emissions Standards for 1995 and

later for Utility and Lawnand Garden Equipment

Engines.

As a California user of these engines,pleasebe

aware that unauthorized modifications or replace-

ment of fuel,exhaust, air intake,or speed control

system components that affect engine emissions

areprohibited. Unauthorized modification, removal

or replacement of the engine label is prohibited.

You should carefully review Operator (Owner),

Installation and other manuals and information you

receive with your engine or equipment.If you are

unsure that the installation, use,maintenance or

serviceof your engine or equipment is authorized,

you should seek assistance from anapproved

Onanengine dealer or anapproved dealer for your

equipment.

Californiaengine users may useTables 4as aids in

locating information related to the California Air Re-

sources Board requirements for emissions control.

TABLE 4. EMISSIONS CONTROL INFORMATION

Engine Warranty Information

The Californiaemissions control warranty statement is located

in the same packet of information as this manual when the en-

gine is shipped from the factory.

Engine ValveLashSee Specifications.

Engine Ignition Timing See Specifications.

Engine Fuel Requirements The engine is certified to operate on unleaded gasoline. See

Fuel Recommendations in Introduction.

Engine Lubricating Oil Requirements See Engine Oil Recommendations in Introduction.

Engine Fuel MixtureSettingsTheseengines have precision-manufactured carburetors

whichare not adjustable.

Engine Adjustments See Adjustments.

Engine Emission Control System The engine emission control system consists of internalengine

modifications.

Important Information

for California Engine Users

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by any means, is strictly prohibited.

Cummins Power Generation

1400 73rdAvenueN.E.

Minneapolis, MN 55432

763-574-5000

Fax: 763-528–7229

Cummins and Onanare registered trademarks of Cummins Inc.

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by any means, is strictly prohibited.